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Old 01-25-2016, 08:58 AM   #14 (permalink)
aardvarcus
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I would design around construction, as the best shell is the one that gets built. I am currently building a shell for my Toyota Tacoma, using XPS foam and will be fiberglassing over it with epoxy. I am about halfway done, and have a thread going on here if you want to see it.

My suggestion is that if the template lands a few inches higher than your tailgate, just build the shell where it is a few inches higher than your tailgate. On my Tacoma, the template landed 5” higher than the tailgate, so I built my shell to match that profile. I chose to extend my shell a few inches back past the tailgate before I terminated it, but I could have ended it right there, and had a vertical drop from the end of the profile. I still might end up cutting that part off before it is all done. Personally I wouldn’t want it to come down to a razor edge right over the tailgate, you need strength right there. With most lightweight construction methods, you need some vertical height there especially if you are incorporating a window. Also I am going to mount my third brake light right there. You don’t want a curve there, you want a nice clean separation where you want the air to let go.
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